EP2883590B1 - Composition de catalyseur à base de vanadate de métal de transition ou de vanadate mixte de métal de transition/de terre rare pour la réduction catalytique sélective des gaz d'échappement - Google Patents
Composition de catalyseur à base de vanadate de métal de transition ou de vanadate mixte de métal de transition/de terre rare pour la réduction catalytique sélective des gaz d'échappement Download PDFInfo
- Publication number
- EP2883590B1 EP2883590B1 EP14192654.3A EP14192654A EP2883590B1 EP 2883590 B1 EP2883590 B1 EP 2883590B1 EP 14192654 A EP14192654 A EP 14192654A EP 2883590 B1 EP2883590 B1 EP 2883590B1
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- EP
- European Patent Office
- Prior art keywords
- catalyst
- tio
- vanadate
- none
- catalyst composition
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 239000003054 catalyst Substances 0.000 title claims description 94
- 239000000203 mixture Substances 0.000 title claims description 69
- 239000007789 gas Substances 0.000 title description 14
- 229910052761 rare earth metal Inorganic materials 0.000 title description 14
- 229910052723 transition metal Inorganic materials 0.000 title description 12
- -1 Transition-metal vanadate Chemical class 0.000 title description 11
- 150000003624 transition metals Chemical class 0.000 title description 8
- 238000010531 catalytic reduction reaction Methods 0.000 title description 2
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- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 65
- 239000000463 material Substances 0.000 claims description 49
- 239000000377 silicon dioxide Substances 0.000 claims description 32
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- 229910052682 stishovite Inorganic materials 0.000 claims description 31
- 229910052905 tridymite Inorganic materials 0.000 claims description 31
- 238000002360 preparation method Methods 0.000 claims description 24
- 238000000034 method Methods 0.000 claims description 17
- 238000001354 calcination Methods 0.000 claims description 14
- 230000008569 process Effects 0.000 claims description 9
- 238000002156 mixing Methods 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 8
- 239000011363 dried mixture Substances 0.000 claims description 3
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- 238000002844 melting Methods 0.000 claims description 3
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- 230000003197 catalytic effect Effects 0.000 description 21
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- AZUYLZMQTIKGSC-UHFFFAOYSA-N 1-[6-[4-(5-chloro-6-methyl-1H-indazol-4-yl)-5-methyl-3-(1-methylindazol-5-yl)pyrazol-1-yl]-2-azaspiro[3.3]heptan-2-yl]prop-2-en-1-one Chemical compound ClC=1C(=C2C=NNC2=CC=1C)C=1C(=NN(C=1C)C1CC2(CN(C2)C(C=C)=O)C1)C=1C=C2C=NN(C2=CC=1)C AZUYLZMQTIKGSC-UHFFFAOYSA-N 0.000 description 1
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- 238000004438 BET method Methods 0.000 description 1
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- 238000005033 Fourier transform infrared spectroscopy Methods 0.000 description 1
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- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- Y02T10/12—Improving ICE efficiencies
Definitions
- the present invention relates to a catalyst composition for selective catalytic reduction of exhaust gases, in the following "catalyst composition", and a process for its preparation.
- a catalyst composition may be used in catalyst application for the removal of NO x , particularly in exhaust gas aftertreatment of diesel- and lean burn engines of automotives.
- the catalyst composition may also be used in stationary applications (e.g. removal of NO x in power plant stations).
- V 2 O 5 doped TiO 2 /WO 3 compositions are used commercially since 1970 to remove nitrogen oxide emissions of fossil fuel power plants.
- a typical SCR system consists of a reduction catalyst, urea injection and dosing components, pipes and a storage tank.
- a huge number of modern catalysts are extruded substrates or coated substrates with Vanadium Pentaoxide (V 2 O 5 ) as the catalytically active component.
- Titania-tungsten oxide based catalysts containing V 2 O 5 as active component are applied for making automotive catalysts in a huge number (approx. 4 Mio. Catalysts/year).
- V 2 O 5 containing materials based on TiO 2 /WO 3 which additionally may contain oxides out of transition metals, Rare Earths and other elements and the application in SCR is widely disclosed in numerous publications, patent applications and patents.
- GB 1 495 396 describes a catalyst composition containing as active ingredients oxides from titanium, at least one of molybdenum, tungsten, iron, vanadium, nickel, cobalt, copper, chromium and uranium, and as optional component(s) tin and/or at least one of silver, beryllium, magnesium, zinc, boron, aluminium, yttrium, rare earth metal, silicon, niobium, antimony, bismuth, manganese, thorium and zirconium, which oxides are present as an intimate mixture.
- EP 787 521 describes the preparation of several V-containing catalysts based on TiO 2 /WO 3 containing additional dopants such as Y 2 O 3 , B 2 O 3 , PbO, SnO 2 the vanadium being present as Vanadiumpentaoxide V 2 O 5 .
- V 2 O 5 containing materials which contain TiO 2 , SiO 2 , S and Oxides of Ce, Sn, Mo and W are reported in UK Appl. GB 2 149 680 .
- EP 1 145 762 A1 describes a process for the preparation of a vanadia SCR-catalyst supported on titania.
- the main disadvantage of the V-based catalyst type is the limited stability at temperatures above 600°C.
- a TiO 2 /WO 3 /V 2 O 5 suitable SCR catalyst for NO x removal of Diesel-powered vehicles is described in US 6 805 849 B1 , column 2. Although such a catalyst has shown good performance it was found that sustained high temperature operation can cause catalyst deactivation. Heavy duty diesel engines, which are almost exclusively charged, can produce exhaust gases at greater than 500°C. Under conditions of high load and/or high speed, and such temperatures deactivation of the catalyst may occur.
- Vanadium based systems with improved thermal stability are also reported by James. W. Girard et al., "Technical Advantages of Vanadium SCR Systems for Diesel NOx Control in Emerging Markets", SAE technical paper 2008-01-132, SAE World Congress Detroit, Michigan Apr 14-17, 2008 . After ageing at 600°C/50 hrs the catalyst is still active. However, because of high exhaust gas temperatures possible during active Diesel Particulate Filter (DPF) regeneration, vanadium SCR catalysts are usually not considered for these applications.
- DPF Diesel Particulate Filter
- NO 2 diesel oxidation catalyst
- DOC diesel oxidation catalyst
- the NO 2 can be used to burn up particulates and to improve the low temperature activity (in the range 180 - 350°C), see M. Rice, R. Mueller at al., Development of an Integrated NOx and PM Reduction Aftertreatment System: SCRi for Advanced Diesel Engines, SAE technical paper 2008-01-132, SAE World Congress Detroit, Michigan Apr 14-17, 2008 .
- the second concept comprises an engine concept which will lead to low concentrations of PM and low NO x concentrations.
- the SCR catalyst may consist of a vanadium based material or a zeolite. Both concepts will use a diesel oxidation catalyst (DOC) prior to the SCR treatment.
- DOC diesel oxidation catalyst
- the problem of low temperature activity of SCR catalysts is also addressed in US 2008/0234126 A1 . It is described a method for the preparation of a vanadium/titania based catalyst with enhanced low temperature activity for removing nitrogen oxides at a window of 300°C and lower. However, US 2008/0234126 A1 does not address the problem of stability of the catalyst > 600°C.
- the vanadium in the formulations based on TiO 2 /WO 3 /(SiO 2 ) is present not in form of Vanadiumpentaoxide (V 2 O 5 ) but in form of a Rare Earth Vanadate (REVO 4 ).
- the Rare Earth vanadate may be introduced to the support material (TiO 2 /WO 3 /(SiO 2 )) as a powder by simple mixing route (of the support and the Rare Earth Vanadate) following by calcination of the mixture.
- the Rare Earth Vanadates may be formed in the composition also in situ during the preparation (calcination) of the catalyst composition from precursors eg. Rare Earth acetate and Ammoniummetavanadate. The presence of the Rare Earth Vanadates in the catalyst is proved by XRD.
- the catalyst compositions referred in WO 2005/046864 A1 exhibit good NO x conversion activity after being heat treated at 750°C / 10 hrs, whereas in contrast the reference material containing V 2 O 5 on the TiO 2 /WO 3 /SiO 2 support may be considered to be almost inactive after being heat treated (aged) at 750°C / 10 hrs.
- WO 2005/046864 A1 does not describe any NO x conversion rates below 250°C, eg at 230°C and 200 °C which is important for the automotive SCR systems.
- an ErVO 4 doped TiO 2 /WO 3 /SiO 2 composition which refers to Example 18, Table 2b in WO 2005/046864 A1 , was subjected to NO x conversion test at temperatures at 200°C and 230°C. NO x conversion was found to be zero at 200° and 230°C and 25 % at 250°C for the "fresh" material.
- Comparative example 1 refers to a commercially available catalyst containing V 2 O 5 supported on TiO 2 /WO 3 /SiO 2 which is currently applied in heavy duty diesel SCR. After heat treatment at 650°C / 2 hrs the material still exhibits activities. However the activity in the range 200 - 250°C is already less than 50%; the activity drops significantly after heat treatment 700°C/10 hrs.
- RE-Vanadate doped TiO 2 /WO 3 /SiO 2 materials are more heat stable compared to the V2O5 doped materials but show a weakness in NO x conversion at operating temperatures below 300°C.
- V 2 O 5 containing TiO 2 /WO 3 /SiO 2 materials seem to be operable up to 650°C but loose already activity.
- the catalyst composition according to the invention is defined in claim 1.
- catalyst compositions comprising TransitionMetal Vanadates and mixed TransitionMetal/RareEarth Vanadates and a support S comprising TiO 2 .
- RareEarth means a RareEarth element or a mixture thereof, i.e. more than one RareEarth element.
- the RareEarth elements are Sc, Y and the fifteen Lanthanides La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm Yb and Lu.
- TransitionMetal means a TransitionMetal element or a mixture thereof, i.e. more than one TransitionMetal element.
- a TransitionMetal is an element whose atom has an incomplete d sub-shell, or which can give rise to cations with an incomplete d sub-shell.
- the term TransitionMetal shall only comprise the elements of groups 4-11 on the periodic table and Zn.
- the present invention is based on the surprising finding that the new compositions based on TiO 2 /WO 3 (TW) or TiO 2 /WO 3 /SiO 2 (TWS) have enhanced heat resistance and enhanced NO x conversion activity when compared to the state of the art materials.
- these new catalyst compositions contain dopants based on Fe-Vanadate. Hence, such compounds may be useful for exhaust gas after treatment of diesel and lean burn engines in combination with a particulate filter in future SCR systems.
- a preferred embodiment is characterized in that S contains SiO 2 in an amount of 4-15 wt.-%, particularly in an amount of 5-10 wt.-%.
- the present invention is also directed to a process for the preparation of the catalyst composition as defined in claim 3.
- a further preferred embodiment is characterized in that the Fe-Vanadate prior to the mixing to the support is pre-heattreated separately, preferably in the range of higher than 350°C and below its melting point, which pre-heattreatment results in a significant increase of the catalytic activity of the catalysts.
- compositions based on the support TiO 2 /WO 3 (TW) and TiO 2 /WO 3 /SiO 2 (TWS) which are doped with Fe-Vanadate according to the invention are preferably produced by a process comprising
- the content of the dopant introduced to the support material is typically 8.4 % by weight but may be applied in lower (0.2 %) and higher concentrations (up to 25 %) also.
- compositions prepared according to the invention were calculated on the content of Vanadium out of the amounts of support and dopant (both analytically well characterised) used for the preparation of the compositions.
- the invention is also directed to a catalyst comprising a catalyst composition as described above and a binder which typically may comprise Al 2 O 3 or Silica.
- compositions were characterised on specific surface area and partly in terms of XRD structure.
- the specific surface area of the materials were measured by BET method using N 2 adsorption/desorption at 77 K employing a Micromeritics Tristar apparatus, after pretreatment under vacuum at 150°C for 1.5 hours.
- compositions were subjected to catalytic testing.
- test A standard test on powder
- test B test with real catalyst
- Powders yielded by the process according to the invention were pressed into pellets, crushed and sieved in the range 355-425 ⁇ m.
- the test was carried out in the apparatus described in figure 1 .
- a model feed gas for NO x component there was used NO only. More in detail the feed consisted of NH 3 /N 2 , NO/N 2 , O 2 , N 2 .
- Mass flow meters were used to measure and control the single gaseous stream while an injection pump was used to introduce water.
- the feed stream was preheated and premixed and ammonia was added to the gaseous mixture immediately before entering the reactor to avoid side reactions.
- a tubular quartz reactor was employed inserted in a furnace. Temperature was controlled by a thermocouple inserted in the catalyst bed. Activity of the catalysts was measured under stationary as well as dynamic conditions (ramp 5°C /min) in a temperature range of 200°C to 480°C. There were no major differences in the results between the 2 methods applied.
- Powders prepared by the process according to the invention were mixed with approx. 20 weight % of Al 2 O 3 binder (pseudo-boehmit) to an aqueous slurry, the slurry coated on a cordierite substrate (honeycomb) and the water removed by hot air.
- the present invention provides compositions based on TiO 2 /WO 3 /SiO 2 (TWS) comprising Fe-Vanadate.
- Fe/Er Vanadate dopants with different molar ratios of Fe/Er in the dopants.
- catalyst mixtures based on TWS with the dopant FeVO 4 exhibit an improved catalytic activity when compared to the reference materials described in comparative example 1 (commercial catalyst based on TWS containing V 2 O 5 ) and in comparative example 2 (TWS containing ErVO 4 ) when prepared under the same conditions as the comparative materials. More of the details are disclosed in table 9.
- compositions based on TWS in which the dopant comprises Fe, Metals of Rare Earths other than Er eg. Sm, Gd or Y; additionally the Fe/Rare Earth Vanadates may contain other transition metals, eg Mn and Zr.
- a FeVO 4 containing catalyst increases the activity dramatically when the dopant is pre-heattreated at 550°C or 700°C prior to the mixing with the support.
- TiO 2 /WO 3 is a well known state of the art process.
- the compound may be prepared applying a description disclosed in US 4 466 947 , example 1, in which Titanic acid is impregnated with ammoniumparatungstate. On drying and calcination of the mixture the TiO 2 /WO 3 compound will be formed.
- ammonium metavanadate (AMV, containing 76.1% V 2 O 5 ) was dissolved in 1100 mL deionised water at 80°C. After mixing the two solutions under continuous stirring, the pH was adjusted to 7.25 by adding 24% ammonia solution. The precipitate so formed was stirred for another half an hour, filtered, washed several times with deionised water and dried at 120°C overnight yielding 50 g of compound 1.
- the Fe 0.5 Er 0.5 VO 4 was analytically characterized by elemental analysis applying X-Ray Fluorescence method (XRF). Table 3- Elemental analysis of Fe 0.5 Er 0.5 VO 4 V (wt%) Fe (wt%) Er (wt%) Calculated 22.49 12.33 36.92 Found 21.52 13.42 36.67
- Compounds 1-5 and 7-15 are vanadates not employed according to the invention.
- Compound 6 (FeVO 4 ) is a vanadate employed according to the present invention.
- the compounds 2-15 were analytically characterized by elemental analysis using XRF-technique and the software program "Uniquant". Due to lack of standardized reference samples the analytical method will have an uncertainty of approx. +/- 5 % in the reported values.
- Metal -Vanadates (compounds 1, 6 and 13 and Comp 2 as listed in table 5) were also subjected to heat treatment in a muffle furnace at temperatures from 500 - 850°C prior to the mixing with the support material TWS (DT 58) for making the catalyst.
- the compounds prepared (Heat treated Metal-Vanadates) and the conditions applied in the heat treatment step are listed in table 5a.
- Two slurries were formed by suspending 0.2523 g of Fe 0.5 Er 0.5 VO 4 in 5 mL deionised water and 2.7477 g of TiO 2 /WO 3 /SiO 2 support material in 10 mL deionised water. The two slurries were mixed and heated up to 90°C while stirring. The slurry was brought to dryness under continuous stirring at 80-100°C and the residue finally dried overnight at 120°C followed by calcinations at 650°C/2h under air in a muffle furnace. Ultimately the so obtained dried mixture was pressed into pellets, crushed and sieved in range 355-425 ⁇ m.
- This material is considered as "fresh” material.
- Aging of sample was carried out by calcination of the material at a temperature of 700°C for 10 hrs and 100 hrs and at 750°C, and at 800°C for 10 hours in air in a muffle furnace.
- the composition refers to a calculated V content of 1.9 %.
- BET of the catalyst composition was measured after calcination at 650°C/ 2 hrs (fresh material), 700°C/ 10 hrs (aged), 700°C/100 hrs, 750°C/10 hrs (aged) and 800°C/10 hrs (aged) and showed a value of 72 m 2 /g, 60 m 2 /g, 39 m 2 /g, 31 m 2 /g and 19 m 2 /g respectiveley.
- Aging of sample was carried out by calcination of the material at a temperature of 700°C for 10 hours in air.
- Aging of sample was carried out by calcination of the material at a temperature of 750°C for 10 hours in air.
- Two slurries were formed by dissolving 0.2523 g of ErVO 4 in 5 mL deionised water and 2.7477 g of TiO 2 /WO 3 /SiO 2 support material in 10 mL deionised water.
- the two slurries were mixed and heated up to 90°C while stirring.
- the slurry was brought to dryness under continuous stirring at 80-100°C and the residue finally dried overnight at 120°C followed by calcinations at 650°C/2h under air in a muffle furnace.
- the so obtained dried mixture was pressed into pellets, crushed and sieved in range 355-425 ⁇ m.
- This material is considered as "fresh” material.
- Aging of sample was carried out by calcination of the material at a temperature of 700°C for 10 hours in air.
- V-content of the catalyst compositions prepared in examples 1a - 15 as well as for the comparative examples 1 and 2 is given in table 7. There are also listed several BET values reported for the materials calcined at different temperatures (range from 650°C up to 800°C) Table 7, Example 1a - 15 and comparative example 1,2; TWS based catalyst compositions, species of dopant, V-content of catalyst compositions and BET values after heat treatment Example Vanadate Species Preheattreatment of Vanadate [°C/hrs] V-content Cat. Comp.
- Standard Test A was performed according to the parameters disclosed in the table 8 Table 8: Reaction condition and gas composition Catalyst weight 100.0 mg Particle size 355-425 ⁇ m Total flow 0.3 l/min Space velocity 180000 h -1 Temperature 200-480°C NO conc. 200 ppm NH 3 conc. 220 ppm O 2 conc. 20000 ppm H 2 O conc. 10% N 2 conc. balance
- Table 9 shows the NO x removal efficiency of the compositions prepared in the examples 1-15 as well as for the comparative example 1 and 2 after heat treatment of the powder at 650°C/ 2hrs.
- Table 10 shows the NO x removal efficiency of the compositions prepared in the examples listed as well as for the comparative example 1 and 2 after heat treatment of the powder at 700°C/ 10 hrs.
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Claims (5)
- Composition catalytique représentée par la formule générale
XVO4/S
dans laquelleX désigne Fe, etS est un support comprenant du TiO2, caractérisé en ce que ledit support contient du TiO2 en une quantité d'au moins 55 % en poids, du WO3 en une quantité de 1 à 20 % en poids, et facultativement du SiO2 en une quantité allant jusqu'à 20 % en poids, ladite composition de catalyseur contenant du XVO4 en une quantité comprise entre 0,2 % en poids et 25 % en poids. - Composition de catalyseur selon la revendication 1, caractérisée en ce que S contient du SiO2 en une quantité de 4 à 15 % en poids, en particulier en une quantité de 5 à 10 % en poids.
- Procédé pour la préparation d'un composition de catalyseur selon l'une quelconque des revendications 1 à 2, comprenant les étapes consistant à :a) mettre en suspension ledit matériau de support contenant du TiO2 et du XVO4 dans de l'eau en formant un mélange intime comprenant ledit matériau support et ledit XVO4,b) évaporer l'excès d'eau,c) sécher le mélange, de préférence à une température comprise entre 80 et 150°C, etd) calciner le mélange séché sous air à une température comprise entre 500 et 850°C.
- Procédé pour la préparation d'une composition de catalyseur selon la revendication 3, caractérisé en ce que du XVO4 est préchauffé à une température dans la plage de plus de 350°C et en dessous de son point de fusion avant le mélange avec le support.
- Utilisation d'une composition selon l'une quelconque des revendications 1 à 2 pour gaz d'échappement après traitement.
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AT6262009 | 2009-04-23 | ||
PCT/AT2010/000116 WO2010121280A1 (fr) | 2009-04-23 | 2010-04-16 | Composition de catalyseur à base de vanadate de métal de transition ou de vanadate mixte de métal de transition/de terre rare pour la réduction catalytique sélective des gaz d'échappement |
EP10715483.3A EP2349531B1 (fr) | 2009-04-23 | 2010-04-16 | Composition de catalyseur à base de vanadate mixte de fer/de terre rare pour la réduction catalytique sélective des gaz d'échappement |
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EP10715483.3A Division-Into EP2349531B1 (fr) | 2009-04-23 | 2010-04-16 | Composition de catalyseur à base de vanadate mixte de fer/de terre rare pour la réduction catalytique sélective des gaz d'échappement |
EP10715483.3A Division EP2349531B1 (fr) | 2009-04-23 | 2010-04-16 | Composition de catalyseur à base de vanadate mixte de fer/de terre rare pour la réduction catalytique sélective des gaz d'échappement |
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EP2883590A1 EP2883590A1 (fr) | 2015-06-17 |
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EP10715483.3A Active EP2349531B1 (fr) | 2009-04-23 | 2010-04-16 | Composition de catalyseur à base de vanadate mixte de fer/de terre rare pour la réduction catalytique sélective des gaz d'échappement |
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US (1) | US8465713B2 (fr) |
EP (2) | EP2883590B1 (fr) |
JP (2) | JP5982280B2 (fr) |
KR (1) | KR101735851B1 (fr) |
CN (1) | CN102421505B (fr) |
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BR (1) | BRPI1015531B1 (fr) |
CA (1) | CA2756736C (fr) |
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HK (1) | HK1165353A1 (fr) |
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MY (1) | MY157440A (fr) |
RU (1) | RU2531195C2 (fr) |
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MY157440A (en) | 2016-06-15 |
CN102421505B (zh) | 2015-01-07 |
TW201114487A (en) | 2011-05-01 |
WO2010121280A1 (fr) | 2010-10-28 |
RU2531195C2 (ru) | 2014-10-20 |
JP2015134350A (ja) | 2015-07-27 |
EP2349531B1 (fr) | 2015-07-01 |
CA2756736A1 (fr) | 2010-10-28 |
EP2883590A1 (fr) | 2015-06-17 |
EP2349531A1 (fr) | 2011-08-03 |
KR101735851B1 (ko) | 2017-05-24 |
US8465713B2 (en) | 2013-06-18 |
JP2012524646A (ja) | 2012-10-18 |
WO2010121280A8 (fr) | 2010-12-29 |
BRPI1015531B1 (pt) | 2020-04-28 |
CA2756736C (fr) | 2017-10-10 |
ZA201107159B (en) | 2012-05-30 |
HK1165353A1 (en) | 2012-10-05 |
CN102421505A (zh) | 2012-04-18 |
RU2011147474A (ru) | 2013-05-27 |
EP2883590C0 (fr) | 2024-06-05 |
US20110150731A1 (en) | 2011-06-23 |
KR20120007062A (ko) | 2012-01-19 |
JP5982280B2 (ja) | 2016-08-31 |
TWI478767B (zh) | 2015-04-01 |
MX2011010613A (es) | 2012-01-20 |
AR076404A1 (es) | 2011-06-08 |
BRPI1015531A2 (pt) | 2016-04-26 |
DK2349531T3 (en) | 2015-09-28 |
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